Method to produce a bonded pile fabric

ABSTRACT

1. A method of manufacturing a cut, pile fabric on a machine having an elongated rotably mounted rotor member having a plurality of rows of apertures therein with the rows of apertures extending in the axial direction of the rotor member comprising the steps of: providing a plurality of yarn supplies of a first color adjacent the rotor member, providing a plurality of yarn supplies of a second color at an angle to the yarns of a first color adjacent the rotor member, supplying certain selected yarns of the first color into certain apertures of one row of the rotor member, severing the certain selected yarns of said first color from its supply, rotating the rotor to a position whereat the apertures of the one row are adjacent the yarns of a second color, supplying certain selected yarns of the second color into other apertures of the one row of apertures of the rotor member, severing the certain selected yarns of said second color from its supply, rotating the rotor member to a position where the one row of apertures is adjacent a yarn receiving adhesive member and simultaneously inserting said first color yarn and said second color yarn from the one row of apertures into the adhesive member.

1974- c. A. W ETHINGTON v 3,343,432

METHOD TO PRODUCE A BONDED FILE FABRIC Filed Jan. 27: 1972 4 Sheets- Sheet 1 9 A. WETHINGTOIN 3,843,

METHOD TO PRODUCE A BONDED FILE FABRIC Filed Jan. 2'7: 1972 4 Sheds-Sheet 2 FIGX-IO- Oct. 22, 1974 c. A. WETHINGTON 3, 3,

METHOD 1'0 PRODUCE A BONDED FILE FABRIC Filed Jan. 2'7, 1972 4 Sheets-Sheet 5 Och 1974 c. A. WETHINGTON 3,843,

METHOD TO PRQDUCE A BONDED FILE FABRIC 4 Sheets-Sheet &

Filed Jan. 27," 1972 Ewe United States Patent 3,843,432 METHOD TO PRODUCE A BONDED PILE FABRIC Charles A. Wethington, Spartanburg, S.C., assignor to Deering Milliken Research Corporation, Spartanburg,

Filed Jan. 27, 1972, $81. No. 221,216 Int. Cl. B32b 5/02, 31/00,- D05c 17/02 US. Cl. 156-72 2 Claims ABSTRACT OF THE DISCLOSURE Prior to this invention the carpet industry has attempted to develop a relatively simple machine to produce a bonded, cut pile carpet which has the appearance of an Axminster carpet.

' Therefore, it is an object of this invention to produce a bonded, cut pile carpet by a machine and process which has colored yarn patterning capability.

Other objects and advantages of the invention will become clearly apparent as the specification proceeds to describe the invention with reference to the accompanying drawings, in which:

' FIGS. 1-5 represent schematically the basic concept of the invention;

FIG. 6 is a partial view of the yarn collector and distributor cylinder;

FIGS. 7 and 8 are schematic representations of two .forins of the individual discs used in the yarn collector FIG. 18 represents a modification of the invention in each of the discs 12. The discs are secured together in any suitable manner to provide an elongated right circular cylinder which is mounted on a horizontal axis to supply bits of yarn 16 and 18 in a substantially perpendicular direction into the adhesive surface 30.

The adhesive surface 30 can be applied to a backing material or, depending on the adhesive, can be applied directly to the conveying surface 32. The particular adhesive could be liquid at the point of yarn insertion requiring heat or time to become a permanent bonding vehicle or could be a hot melt requiring only cooling. The adhesive surface 30 can be planar at the point of yarn insertion as shown in FIGS. 14 and 16 or can be curved at the point of insertion as shown in FIGS. 1-6 and 15.

Looking at FIG. 17 a typical yarn feed is illustrated in that air is aspirated into the needle 34 to suck the yarn 20 into the radial opening 22 until it bottoms on the Patented Oct. .22, 1974 "ice bottom 36 of the opening. If desired, the passage 38 can be vented to atmosphere to allow the yarn to be more readily fed into the opening 22. In the desired form of the invention the length of the yarn 20 to be cut is de termined by the depth of the opening 22 but other devices, such as a solenoid controlled stepping motor, can be used to deliver a desired length of yarn into the opening 22. As shown in FIGS. 1-5 the yarn bits are cut from the ,yarn supplies 20 and 21 by a fixed knife blade 40, or other suitable means such as a shear, band knife or sickle bar cutter, located adjacent the yarn supply so that it engages the yarn as the yarn distributor rotates to sever the bits from the yarn supply.

FIGS. 9-11 show the preferred yarn releaseand bit inserter device and FIGS. 12 and 13 show-an alternative device. In FIGS. 911 when the cyliner 12 rotates to a position vvhere one of the radial holes, such as 22, is lined up with the hollow needle 42 and it is desired to insert the bit of yarn 16 into the adhesive layer 30, the passage 38 is vented to atmosphere and air is aspirated into the needle 42 through opening 44 to insert the yarn bit 16 into the adhesive layer 30. Then the conveying surface 32 is moved downward (FIG. 10) so that the yarn bit 16 clears the bottom of the needle 42. Then the conveying surface is moved downstream from the needle and upward for receipt of another row of yarn bits if the row of yarn is complete with the proper colors. At the same time the cylinder 12 has rotated counterclockwise to place another radial opening, such as 28, into communicationwith the hollow needle 42. 1

FIGS. 12 and 13 illustrate another type of yarn inserter which may be employed to implant yarn bits 16 into the adhesive layer 30. The yarn inserter of FIGS. 12 and 13 is a mechanical type which uses a plunger 45 and plunger rod 46 to mechanically push the yarn bit 16 into the adhesive surface 30. The plunger 46 can be actuated by any suitable means such as a cam, solenoid, etc.

It 'is understood that there are a series of yarn supply devices and yarn delivery devices lined up in a substantially parallel position to supply a multiplicity of yarn bits into the adhesive surface 30 at one time toproduce a row of yarn bits.

FIGS. l-S represent schematically the operation of one disc ofone cylinder 10. For the sake of discussion, let us assume it is desired to provide a carpet with a two color yarn effect. The control of the yarn into and out of the radial opening, as well as the rotation of the cylinder 10, is automatic and preselected to provide the desired effect in the finished product. If N represents the number of yarn colors required, the discs 12 will have 2N openings therein as indicated by the openings 22, 24, 26 and 28 since a two color yarn effect is desired. The number of openings in the disc 12 for any N is such that there will be N openings in a position to be fed yarn. N1 openings empty or idle and one opening in a position to release yarn into the adhesive layer. The control is so selected that only one color yarn is released at any one time so each indexing rotation of the cylinder 10 is 1r/ N radians. Thus the maximum number of indexes necessary for a given yarn color to become available at the release station at a given place in the pattern also will be N. To express it another way, if it is desired that all colors are to be placed in a single row in the adhesive, the cylinder 10 will be rotated or indexed N times before the backing 32 is moved to make another row in the carpet.

As shown in FIGS 1-5, one color yarn is supplied only to openings 22 and 26 while the other color yarn is supplied to openings 24 and 28. Looking now to FIG. 1 and assuming that the controls are programmed to do so, one color yarn 20 is being supplied to opening 22 while another color yarn 21 is being supplied to the opening 24.

At the same-time, yarn bit 16 which has'been cut from he-yam supply 2,0,,is. being releasedtinto thev adhesive-J,

supplies 20 and-;21 by the knives 40 apppropriately located in the path of travel of the cylinder 10. Then the cylinder .10 reaches the position shown in FIGS. 3 and 4. Whenthe cylinder reaches the position shown in FIG.Y3, the conveying surface 32 is moved upward so that the yarn bit 18 can be'released into the adhesive surface 30 as shown in FIG. 4. Since yarn bit 16 is located in-o'pening 22 no yarn is supplied from yarn supply 21 and no yarn is supplied from yarn. supply 20' into the opening 28. Then, as shown in FIG. 5, the conveying surface 32 is moved downward, indexed one space to receive:another row of yarn bits and moved back up into yarn receiving position.'At the same time, yarn sup- ,ply 20 is supplying yarn into opening 26 and'yarn sup- .ply 21 is supplying yarn into opening 28. Then the procedure is repeated to provide another row of yarn bits.

' In'the above-described type of system a complicated array of actuating devices is necessary for each disc 12 s nce each disc has to have actuation at each of N+l stations since there is selective release of only one color yarn at the release station, thereby requiring a number of actuation devices equal to (N +1) x number of discs 12 for the cylinder 10. The schematic representation of FIG. 18 reduces this number to (N x number of discs 12+l) since all the bottom holes release yarn on each index of the discs, thereby requiring only one release mechanism for all the discs in the cylinder 10. 'Also the number of indexes of cylinder per row of yarn is reduced to one index per row.

Looking now to FIG 18, a modification of the system shown in FIGS. l-S is schematically represented. For the sake of discussion let us assume a two yarn pattern is required and the pattern is to repeat every fourrows. As in FIGS. 1-5, the reference number 16 represents one color yarn and the reference number 18 represents another color yarn. The letters A-E represent discs 12 in the cylinder 10 and the letters R R R R and R represent rows of yarn bits. The yarn bits are supplied and released in the manner previously disclosed. Preferably the supply and release actuation devices are programmed on a computer which, at the predetermined time for the particular desired pattern, ac? tuates the actuators. As pointed out above, FIG. 18 represents a two color repeat pattern but obviously any number of yarns and patterns can be employed within the physical capabilities of the apparatus.

R represents the first row in the carpet being produced and bottom openings of A, B and E are supplying yarn bits 16 and bottom openings of C and D are supplying yarn bits 18. At the same time yarn for bits 16 to be released at row R are being supplied to C and D while yarn for bits 18 are being supplied as and C for release at row R Then the discs 12 are rotated to the R position where A, D and E release yarn bits 16 and B and C release yarn bits 18. At the same time yarn for bits 16 are being supplied to B and C for release at row R while yarn is being supplied to 1A, B and E for release at row 3 .7 s Once again the discs are rotated to row R, where A,

--B and 13 release yarn bits 18 and C and D release yarn 1 6. At the same time yarn for bits 1 6 isbeing supplied to-v A, B and E for release at row R which is identical to R and yarn for bits 18 to be released at row R is being supplied to discs A, D and E for release at row R The discs 12 are rotated to release yarn bits for row R; where A, D and Erelease yarn bits 18-while B and C release yarns bits 16. At the same time discs 'A, D and E are" receiving yarn for yarn bits 16 to be released on the r epeat'of row R while yarn for yarn bits 18'is being supplied to 'C and Dto be released at row 3 Ihen the discs are rotated to row R position and the above-described pattern is repeated. g

As noted, the above-described operation is for a repeat pattern but obviously yarn bits can be supplied by a programmer which does not repeat the pattern.

As described, the herein-disclosed invention provides apparatus and methods which can be computer controlled for manufacturing bonded, cut pile carpets with colored yarn patterning capability.

Although I have described in detail the preferredtembodiments of my invention, I contemplate that many changes may be made without departing from the scope or spirit of my invention and I desire to be limited only member having a plurality of rows of apertures therein with the rows of apertures extending in the axial'direction of the rotor member comprising the steps of: providing a plurality of yarn supplies of a first color adjacent the rotor member, providing a plurality of yarn supplies of a second color at an angle to the yarns of a first color adjacent the rotor member, supplying certain vselected yarns of the first color into certain apertures of one row of the rotor member, severing the certain selected yarns of said first color from its supply, rotating the rotor to a position whereat the apertures of the one row are adjacent the yarns of a second color, supplying certain selected yarns of the second color into other apertures of the one row of apertures of the rotor member, severing the certain selected yarns of said second color from its supply, rotating the rotor member to a position where the one row of apertures is adjacent a yarn receiving adhesive member and simultaneously inserting said first color yarn and said second color yarn from the one row of apertures into the adhesive member.

2. The method of Claim 1 wherein yarn of said first color and said second color is being supplied to other apertures in other rows of apertures while yarn is being "inserted into said adhesive member.

References Cited UNITED CHARLES E. VAN HORN, Primary Examiner T.BOKAN,Assistant=Examiner' V UNITED STATES PATENT OFFICE (:ERTIFICATE OF CORRECTION Patent No. 3341432 Dated g mb 22 191i Inv Charles A, Wethington It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

I Column 2, line 16, the word "cyliner" should read --cylinder--.

Coluinn 2.,- line 54, the after the word yern should be a.

Signed and sealed this 17th day of December 1974.

(SEAL) Attest: I

iicCOY M. GIBSON JR. V c. MARSHALLJD'ANN if ttesting Officer Commissioner of Patents 

1. A method of manufacturing a cut, pile fabric on a machine having an elongated rotably mounted rotor member having a plurality of rows of apertures therein with the rows of apertures extending in the axial direction of the rotor member comprising the steps of: providing a plurality of yarn supplies of a first color adjacent the rotor member, providing a plurality of yarn supplies of a second color at an angle to the yarns of a first color adjacent the rotor member, supplying certain selected yarns of the first color into certain apertures of one row of the rotor member, severing the certain selected yarns of said first color from its supply, rotating the rotor to a position whereat the apertures of the one row are adjacent the yarns of a second color, supplying certain selected yarns of the second color into other apertures of the one row of apertures of the rotor member, severing the certain selected yarns of said second color from its supply, rotating the rotor member to a position where the one row of apertures is adjacent a yarn receiving adhesive member and simultaneously inserting said first color yarn and said second color yarn from the one row of apertures into the adhesive member. 